Duct Supporting Apparatus

ABSTRACT

Disclosed herein is an apparatus and method for supporting a flexible duct. The apparatus comprises a concave duct support structure with a convoluted anterior end and one or more straps. The concave duct support structure is placed in contact with outer surface of the flexible duct. The convoluted anterior end supports curved surfaces of the flexible duct. The concave duct support structure comprises multiple slits. The straps pass through the slits of the concave duct support structure. Distal ends of the straps may be affixed to a structural member for suspending the flexible duct supported on the concave duct support structure. The concave duct support structure prevents the flexible duct from sagging and crimping, thereby allowing free flow of air, liquids, etc. through the flexible duct.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of provisional patent application No. 60/974,517 titled “Duct Saddle Strapping System”, filed on Sep. 24, 2007 in the United States Patent and Trademark Office.

BACKGROUND

This invention, in general, relates to support devices. More particularly, this invention relates to an apparatus for supporting a flexible duct.

A duct is a tube or pipe used for conveying a liquid or a gas. Ducts are typically used in a heating, ventilating, and air conditioning (HVAC) system. Flexible ducts tolerate 3-dimensional movement and are lightweight. Flexible ducting is used in an HVAC system for transferring air flow in and out of a space. A suitable ducting system is needed for distributing warm and cold air in an enclosed space, for example, a room of a building. If the ducting system is not properly designed and installed, there are potential inefficiencies and energy wastage. Typically, metal strapping is used for supporting ducts to a rafter or a beam. Flexible ducting in residential and commercial applications for an HVAC system are typically secured to a beam or rafter by metal strapping using a hammer, a nail, or a screw gun during installation. The metal strapping is expensive and cumbersome to install because an installer has to hold the metal strapping in place with one hand while holding the nail with the same hand and at the same time swinging the hammer with the other hand provided there is enough room to swing the hammer.

The above installation procedure often does not adequately support the flexible duct due to the small contact area of the metal strapping with the flexible duct. Because of the difficulty of securing the strapping for supporting the flexible duct, most installers tend to stretch the spacing as far as possible in order to avoid repeating the difficult strapping procedure as few times as possible. As a result, due to the minimal contact area of the metal strapping that supports the duct and the distance between the metal strapping causes the duct to sag and crimp, which results in restricted airflow through the entire ducting system, affecting the overall efficiency of the HVAC system.

Hence, there is a need for a structure to support a flexible duct. Furthermore, there is a need for the structure to support curved surfaces of the flexible duct to avoid sagging and crimping and allow free flow of air, liquids, etc. through the flexible duct.

SUMMARY OF THE INVENTION

This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description of the invention. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter.

The apparatus and method disclosed herein addresses the above stated needs for an apparatus for supporting a flexible duct. The apparatus and method disclosed herein further supports curved surfaces of the flexible duct to avoid sagging and crimping, thereby allowing free flow of air, liquids, etc. through the flexible duct.

The apparatus disclosed herein comprises a concave duct support structure with a convoluted anterior end and one or more of multiple straps. The concave duct support structure is placed in contact with outer surface of the flexible duct. The convoluted anterior end supports curved surfaces of the flexible duct. The concave duct support structure may be made, for example, of a synthetic material. The concave duct support structure further comprises multiple slits. The straps pass through the slits of the concave duct support structure. The straps may be made, for example, of a synthetic material or a metallic material. Distal ends of the straps are affixed to a structural member for suspending the flexible duct supported on the concave duct support structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. However, the invention is not limited to the specific methods and instrumentalities disclosed herein.

FIG. 1 illustrates an apparatus for supporting a flexible duct.

FIG. 2 exemplarily illustrates a side view of the apparatus, the flexible duct, and a structural member.

FIG. 3 exemplarily illustrates a concave duct support structure with a single strap passing through a single slit of the concave duct support structure.

FIG. 4 exemplarily illustrates suspension of a flexible duct supported on the concave duct support structure using a single strap affixed to the structural member.

FIG. 5 exemplarily illustrates a front sectional view of the flexible duct supported on the concave duct support structure suspended by a single strap affixed to the structural member.

FIG. 6 exemplarily illustrates the flexible duct supported on two concave duct support structures suspended by multiple straps.

FIG. 7 illustrates a method of supporting a flexible duct.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an apparatus 100 for supporting a flexible duct 201. The apparatus 100 may, for example, support the flexible duct 201 in a heating, ventilating, and air conditioning (HVAC) system.

The apparatus 100 comprises a concave duct support structure 101 herein referred to as a “saddle”. The saddle 101 may be made of a lightweight synthetic material, for example, a plastic that is inexpensive and possesses the structural strength to support a flexible duct 201. The saddle 101 has a convoluted anterior end 102. The convoluted anterior end 102 of the saddle 101 supports curved surfaces of flexible duct 201. The convoluted anterior end 102 of the saddle 101 is an angular bend, for example, a 90° bend, that may be used for supporting turns in the flexible duct 201 in the duct run. If several turns are required in a short space of the flexible duct 201, two saddles may be overlapped to form an inverted U shaped saddle. The apparatus 100 may therefore be used for supporting flexible ducts that are straight, or that turn, or are curved or bent. If several bends are required, several saddles are overlapped to provide the necessary support for the flexible duct 201. The saddle 101 may therefore be used for straight supports and bends interchangeably.

Openings 105 are optionally provided in the saddle 101 for reducing the amount of synthetic material, for example, plastic, used for the manufacture of the saddle 101. The openings 105 may be of any shape and size provided the openings 105 do not affect the structural strength and rigidity of the saddle 101 for the saddle's 101 intended function, namely, providing support for the flexible duct 201.

The saddle 101 prevents the flexible duct 201 from sagging and crimping, thereby allowing free flow of air, liquids, etc. through the flexible duct 201. The saddle 101 is a rigid support designed to allow proper airflow through the HVAC system. The saddle 101 is placed in contact with outer surface of the flexible duct 201. The saddle 101 provides more surface contact area with the outer surface of the flexible duct 201, thereby providing the necessary support to the flexible duct 201.

The saddle 101 further comprises multiple slits 103. The saddle 101 further comprises one or more of multiple straps 104. The straps 104 may be made, for example, of a synthetic material or a metallic material. For example, the straps 104 may be made of plastic, wire, vinyl, metal, etc. The straps 104 may also be made of a flexible plastic. The saddle 101 does not require an adhesive to remain in contact with the outer surface of the flexible duct 201. The straps 104 pass through the slits 103 of the saddle 101. Distal ends of the straps 104 are affixed to a structural member 202. A side view of the apparatus 100, the flexible duct 201, and a structural member 202 is exemplarily illustrated in FIG. 2. A single strap 104 a passing through a single slit 103 a is exemplarily illustrated in FIGS. 1-5. Two straps 104 passing through two slits of the saddle 101 is exemplarily illustrated in FIG. 6.

The saddle 101 may use a single strap 104 a for suspending the flexible duct 201 from the structural member 202. FIG. 3 exemplarily illustrates the saddle 101 with a single strap 104 a passing through a single slit 103 a of the saddle 101. Multiple straps 104 may also be used to suspend the flexible duct 201 where the flexible duct 201 bends into a supply boot 601 as exemplarily illustrated in FIG. 6. A second strap may be used at apex of the bend to provide resistance to keep the flexible duct 201 from springing backward and sagging. Distal ends of the straps 104 are affixed to a structural member 202 for suspending the flexible duct 201 supported on the saddle 101. The structural member 202 may, for example, be a rafter, a beam, etc. The distal ends of the straps 104 are affixed to the structural member 202 using devices that make the installation process easier and faster. For example, a stapler may be used for affixing the distal ends of the straps 104 to the structural member 202. The distal ends of the straps 104 may be affixed to the structural member 202 by affixing both distal ends of the straps 104 to the structural member 202. Alternatively, one distal end of each of the straps 104 may be inserted through a loop 104 b of the other distal end and affixed to the structural member 202 as illustrated in FIG. 4 and FIG. 5.

The saddle 101 may be made of a plastic, for example, polypropylene. Polypropylene is inexpensive, safe to work with, and easier and faster to install the apparatus 100 with a stapler. The flexible duct 201 supported on the saddle 101 is suspended by a single strap 104 a affixed to the structural member 202 as exemplarily illustrated in FIG. 4. A front sectional view of the flexible duct 201 supported on the saddle 101 suspended by a single strap 104 a affixed to the structural member 202 is exemplarily illustrated in FIG. 5. The apparatus 100 supports the flexible duct 201 and enables free flow of fluids through the flexible duct 201. The apparatus 100 also reduces installation time of the ducting.

FIG. 7 illustrates a method of supporting a flexible duct. An apparatus is provided 701 for supporting the flexible duct. The apparatus comprises a saddle and one or more straps. The saddle has a convoluted anterior end and multiple slits. One or more straps are passed 702 through the slits of the saddle. The saddle with the convoluted anterior end is placed 703 in contact with outer surface of the flexible duct. The convoluted anterior end supports curved surfaces of the flexible duct. Distal ends of the straps are affixed 704 to a structural member. The distal ends are affixed to the structural member using a device, for example, a stapler. The distal ends of the strap may be affixed to the structural member by affixing both distal ends of the straps to the structural member. Alternatively, one distal end of each of the straps may be inserted through a loop of the other distal end and affixed to the structural member as illustrated in FIG. 4 and FIG. 5. The flexible duct supported on the saddle is suspended 705 from the structural member using the straps. The apparatus thereby supports the flexible duct. The apparatus also enables an easy and fast installation process by an installer.

Consider an example where an installer needs to provide support for a flexible duct 201 in the ducting of an HVAC system. The installer measures and cuts a single strap 104 a to an appropriate length using, for example, a pair of scissors. The installer passes the strap 104 a through a slit 103 a on the saddle 101. The installer places the saddle 101 with the convoluted anterior end 102 in contact with the outer surface of a flexible duct 201. The installer then staples the distal ends of the strap 104 a to a rafter using, for example, a stapler. The strap 104 a suspends the flexible duct 201 supported on the saddle 101 from the rafter. The installer therefore with the aid of the apparatus 100 supports the flexible duct 201 used in the ducting of the HVAC system.

The apparatus 100 may further use metal strapping or wire instead of lightweight plastic straps when required. The apparatus 100 may be of different sizes for accommodating different sizes of flexible ducts. The apparatus 100 is designed to fit different configurations and applications.

The foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention disclosed herein. While the invention has been described with reference to various embodiments, it is understood that the words, which have been used herein, are words of description and illustration, rather than words of limitation. Further, although the invention has been described herein with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed herein; rather, the invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. Those skilled in the art, having the benefit of the teachings of this specification, may effect numerous modifications thereto and changes may be made without departing from the scope and spirit of the invention in its aspects 

1. An apparatus for supporting a flexible duct, comprising: a concave duct support structure with a convoluted anterior end placed in contact with outer surface of said flexible duct, wherein said convoluted anterior end supports curved surfaces of the flexible duct; said concave duct support structure comprising a plurality of slits; and one or more of a plurality of straps passing through said slits of the concave duct support structure, wherein distal ends of said straps are affixed to a structural member for suspending the flexible duct supported on the concave duct support structure; whereby said apparatus supports the flexible duct and enables free flow of air through the flexible duct.
 2. The apparatus of claim 1, wherein the concave duct support structure is made of a synthetic material.
 3. The apparatus of claim 1, wherein the straps are made of one of a synthetic material and a metallic material.
 4. The apparatus of claim 1, wherein the concave duct support structure prevents the flexible duct from sagging and crimping, thereby allowing said free flow of air and liquids through the flexible duct.
 5. A method of supporting a flexible duct, comprising the steps of: providing an apparatus comprising: a concave duct support structure with a convoluted anterior end; said concave duct support structure comprising a plurality of slits; and one or more of a plurality of straps; passing said straps through said slits of the concave duct support structure; placing the concave duct support structure with said convoluted anterior end in contact with outer surface of a flexible duct, wherein said convoluted anterior end supports curved surfaces of the flexible duct; and affixing distal ends of the straps to a structural member for suspending the flexible duct supported on the concave duct support structure.
 6. The method of claim 5, said step of affixing is performed by affixing both the distal ends of each of the straps to the structural member.
 7. The method of claim 5, said step of affixing is performed by inserting one distal end of each of the straps through a loop of other distal end and affixing said one distal end to the structural member. 